Structural unit body and a structure assembled of the unit bodies

ABSTRACT

A structural unit body comprises an outer flange extending outwardly from the edge of a box-like frame plate and an inner flange extending inwardly from the other edge. A stuffed box is secured by anchoring means to the inner flange, such stuffed box being made of dampproof material covered with a metal net and stuffed with noncombustible materials of mineral or inorganic fibers. Cement mortar is applied to the frame plate, inner flange and to the metal net of the stuffed box and a circumferential groove is formed between the outer flange and the underside of the cement mortar.

United States Patent Megumi 1 Sept. 9, 1975 [5 STRUCTURAL UNIT BODY AND A 2,178,097 10/1939 Davison et al. 52/600 X STRUCTURE ASSEMBLED OF THE UNIT 2,262,899 1 1/1941 MeChlin .1 52/405 X BODIES 2,351,856 6/1944 Henderson.. 52/601 X 3,389,560 6/1968 Zemsky 52/587 X [75] Inventor: Naomitsu Megumi, Funabashi, 3,512,327 5/1970 Padura 52/612 Japan 3,676,973 7/1972 Kellert 52/601 X [73] Assignees: Naomitsu Megumi, Funabashi; FOREIGN PATENTS OR APPLICATIONS Tokyo Plywood Kabushiki Kaisha, 481,597 3/1952 Canada 52/612 Tokyo, both of Japan 469,822 12/1950 Canada 1. 52/600 Filed: Nov. 5, 1973 Appl. No; 413,052

52/477; 52/612 Int. Cl. E04B 2/58; E04B 1/76; E04B 1/04 Primary Examiner-Frank L. Abbott Assistant Examiner-Leslie A. Braun Attorney, Agent, or FirmFrank J, Jordan 1 ABSTRACT A structural unit body comprises an outer flange extending outwardly from the edge of a box-like frame plate and an inner flange extending inwardly from the other edge, A stuffed box is secured by anchoring means to the inner flange, such stuffed box being made of dampproof material covered with a metal net [58] Field of Search 52/612, 267, 405, 268,

52/406 269 727 503- 600 504 60L 587 and stuffed w1th noncombustlble matenals of mmera] 1 i a 1 or inorganic fibers. Cement mortar is applied to the frame plate, inner flange and to the metal net of the [56) S Xf E SZ, stuffed box and a circumferential groove is formed between the outer flange and the underside of the ce- 937,635 10/1909 Nicholls 1. 52/405 x mam mortar l 879,3l9 9/1932 Kleitz l 2,089,045 8/1937 Venzic .1 52/606 x 7 laim 7 Drawing Flgul'es 8 l0 6 ll 7 5 8 l 9 2 1 1 1 1 1 1 1 9 j 1' i 5 l5 Q If .i 10 t I- z l I X 1 4 PATENTED 9|975 3,903,668

sum 1 q g PATENTED 9|975 3,903,668

sum 3 pg 9 PATENTEU SEP 9 975 FIG. 6

STRUCTURAL UNIT BODY AND A STRUCTURE ASSEMBLEI) OF THE UNIT BODIES BACKGROUND OF THE INVENTION This invention relates to a structural unit body for covering a structure such as a wall, floor and the like and to a structure assembled from such unit bodies.

The structural unit body of this invention comprises a flat box made of a moisture-proof material covered with a metal net and having a noncombustible material disposed within the box, the latter in turn being anchored to a frame. The whole of the assembly is plastered with mortar except for a certain part of the frame. Also, this invention relates to a structure consisting of an assembly made up of a plurality of such structural bodies. Since the structural unit bodies and the struc ture are fireproof, resilient, strong, and less subject to the effects of temperature and moisture and have sound insulation properties, they can provide a'comfortable dwelling and construction capable of meeting variable environmental conditions.

A description will hereinafter be set forth relative to various embodiments of the invention with reference to the accompanying drawings.

SUMMARY OF THE INVENTION A structural unit body includes a frame having an outer flange and an inner flange arranged such that the inner flange circumscribes an opening in the frame. A stuffing box in which a noncombustible material is disposed is secured to the frame by anchoring means to thereby close off the aforementioned opening in the frame. Cement mortar is disposed on at least a portion of the stuffing box and the frame and such cement mortar is arranged relative to the outer flange to form a circumferential groove between the cement mortar and the outer flange of the frame.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevational view, partly broken away and in section, of a structural unit body according to one embodiment of the invention;

FIG. 2 is a perspective view partly broken away and in section of the structural unit body shown in FIG. I;

FIG. 3 is a cross sectional view of a structure assembled with the unit bodies shown in FIGS. 1 and 2;

FIG. 4 is an elevational view, partly broken away and in section, of a structural unit body according to another embodiment of the invention;

FIG. 5 is a perspective view, partly broken away and in section, of the structural unit body shown in FIG. 4;

FIG. 6 is a perspective view looking at the back side of the structural unit body shown in FIGS. 4 and 5; and

FIG. 7 is a cross sectional view of a structure assem bled with the unit bodies shown in FIGS. 4 and 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Example 1 A description will first be set forth relating to the structural unit body shown in FIGS. 1 and 2 and the structure assembled from these unit bodies as shown in FIG. 3. In FIGS. I and 2, an outwardly facing outer flange 4 on one end edge of a square box-like frame plate 3 made of a metal plate or a noncombustible hard material is constructed in a step-like manner integrally with an inwardly facing inner flange 2 on the other end edge to thereby form a step-like frame I having an opening 17 formed on the upper surface of the inner flange 2. In this connection, the outer flange 4 extends circumferentially at the bottom and defines a flat base. Also the inner flange 2 has a flat upper surface with an opening 17, and the flange is provided with anchoring means such as bolts 6, nuts 7, or the like. A square flat box I5 is provided and the surfaces thereof have a cover 9 made of moisture-proof paper, hard board or particle board which in turn is covered with a metal net 5. The box is stuffed with a noncombustible material 8 such as inorganic fibers, mineral fibers, nonwoven cloth, felt-like material, and the like to thereby form a stuffed box 10, the box 10 thus finished being secured and tightened by the anchoring means 6, 7 and 11 on the inner flange 2 and the opening 17 is closed. Then cement mortar mortar 12 is applied and hardened in a specified shape to the entire surfaces of the inner flange 2, the anchoring means, and the metal net from the upper part of the middle of the frame plate 3 to thereby construct the unit body 13. In the unit body, there is formed a space between the outer flange 4 of the frame plate 3 and the bottom of the cement mortar 12 to thereby form a circumferential groove 14 about the entire circumference, so that a connection plate, as will hereinafter be described in greater detail, can be inserted into the circumferential groove 14. Thus the outer flange 4 becomes a base which can be fixed to a wall or floor by use of fitting holes 16 provided in the flange 4.

In the structural unit body as illustrated, a piece of steel sheet may be punched out to form the frame 1 integrally having the outer flange 4 provided with the fitting holes l6 therein, the flange 2 having the opening 17 therein, and the frame plate 3, wherein the noncom bustible material 8, in addition to the other materials hereinabove, may be a lightweight inorganic material such as vermiculite, pearlite, and the like. The metal net 5 may be formed by punching out a metal sheet such as an iron sheet or it may be made of woven wire. Because the exposed parts of the metal net 5 and the inner flange are allowed to be used and solidified as steel bars for the cement mortar 12, the mortar 12 is strong.

FIG. 3 shows a structure assembled with the aforestated unit bodies. As shown in FIG. 3 the unit body is fixed to a structure 18 such as a wall, floor or the like by anchoring means 22 passing through the fitting holes 16 in the outer flange 4 of the frame I in the unit body 13. Connecting plates 21 are inserted into the circumferential grooves 14 to thereby connect the structural unit bodies I3 to each other in each direction to thereby extend the assembled unit bodies 13, and thereafter a mortar joint or expansion joint 19 is filled in the spaces between the connected parts and fixed. In this manner, a structure can be assembled as shown in FIG. 3.

EXAMPLE 2 A description will now be set forth relating to the structural unit bodies shown in FIGS. 4, S and 6 and the structure assembled from these unit bodies.

In FIGS. 4, 5 and 6, one side edge of a metal sheet having numerous holes 31 formed regularly or irregularly is bent in a right-angled L-shape so as to form an inwardly facing inner flange 36, and the other side edge is bent to form a U-shaped box 34 in which there is stufied a resilient buffer material 33, the arrangement just described thereby forming a step-like base 35. The base 35 thus formed, as shown in FIG. 6, is assembled or joined at four corners so as to form a square frame 32 having an inner flange 36, side walls or frame plate 37 and outer flange 38. An opening 51 is formed in the middle of the inner flange 36 at the circumferential edge of the flange 36. Separately, as shown in FIGS. 4 and 5, there is provided a flat box 39 having a cover 44 made of a moisture-proof material such as moistureproof paper, hard board, particle board or the like and covered with a metal net such box being stuffed with a non-combustible material 43 such as inorganic fibers, mineral fibers, nonwoven cloth and feltlike material made thereof, and the like. A stuffed box 45 of this same type is fastened to the surface of the inner flange 36 by anchoring means such as bolts 41, nuts 42 and 46 and the like, whereby the opening 51 and the holes 31 in the inner flange 36 are closed. Cement mortar 47 is plastered in a specified shape and fixed to the whole of the surface of the top portion of the side walls 37, inner flange, anchoring means and stuffed box to thereby form a structural unit body 48. This unit body also is formed with a circumferential groove 49 between the outer flange 38 and the mortar 47.

In the embodiment of FIGS. 4, 5 and 6, the metal sheet having holes 31 is used as a base 35, but alternatively a metal net made of strong and thick wire may be used instead. The quality of the material used in each part is the same as that in Example 1. The buffer material 33 inserted into the box 34 of the base 35 may be a resilient material of antiseptically treated wood, plywood or synthetic resin.

FIG. 7 shows a structure assembled with the aforestated structural unit bodies. As shown in FIG. 7 the outer frame 38 or the structural unit bodies are mounted on a structural body 52 such as a wall, floor, or the like and unit bodies are connected to each other and assembled in various directions by inserting connecting plates 50 into the circumferential grooves 49 of the structural unit bodies 48. The joint 53 is filled and all the members are set and assembled to construct a structure as shown in FIG. 7.

This invention is embodied for industrial applications in the manner described above, and each structural unit body as a whole is highly resistant to impacts from outside so that the step-like frame itself is strong and resilient and also the stuffed box containing noncombustible materials also affords resilience. Even if there are differences in temperature and moisture between the upper surface and the underside of the cement mortar layer depending upon the climatic conditions, the stuffed box becomes a buffer zone for the temperature difference, so that there is little or no fear of cracks and fissures being produced. For example, when it is rainy or snowy or humid, and even if moisture permeates the inner part of the unit body through the cement mortar layer on the surface of the stuffed box, the moisture is absorbed by the square box enclosing the inorganic fiber materials by atomizing and capillary phenomena due to the action of the air present between the inor' ganic fibers and the effect of moisture is attenuated by the air around the metal net area. If. in the square box, the nuts 7 and 42 inside of the box are designed or selected with a definite size and thickness, the noncombustible materials inside of the box are not compressed but contain a specified amount of air, and accordingly, the effect described above can always be achieved or utilized to a sufficient extent. The cement mortar applied surface including the circumferential groove is large in area and in surface area of contact with the atmosphere, and hence it has the advantage that the transmission of atmosphere temperature to the structure is reduced to thereby maintain suitable heat retaining properties. Since a structure made up, in suitable combination, of structural unit bodies is connected by connecting plates, the whole of the structure constitutes walls and floors which are resistant to vibration, and hence the structure can resist earthquakes. Furthermore, it acquires desirable properties such as resilience, pliability, fire resistance, shock resistance and the like.

As described above, this invention permits the respective members of a structure to bring their mutual effectiveness into full play with the state of their functions being maintained and thus provides a comfortable and noncombustible structure that is adaptable to environmental conditions and excellent also in sound and heat insulation properties. Furthermore, the structure is strong and corrosion resistant, and accordingly it can withstand usage over a long time. Because the structure is prepared as an assembly, it is simple in construction, and affords decorative effects depending upon the style and state in which the unit bodies are arranged, and because it is lighter in weight than the conventional concrete blocks, it is convenient both for transportation and in handling. Because the structure shown in Example 2 is provided in the whole of the frame with holes 31, it provides good adaptability, stability and safety are increased, and moreover it is less influenced by temperature and humidity. It also provides heat and sound insulation properties on a structure 52, and therefore provides a structure that makes a dwelling comfortable and adapted for variable environmental conditions.

l claim:

1. A prefabricated structural unit body adapted to be affixed to a structural member comprising a four sided frame with each side having a frame plate along with an outer flange and an inner flange, said outer flange extending outwardly and said inner flange extending inwardly from said frame plate, said inner flange circumscribing an opening in said frame, a stuffing box, a noncombustible material within said stuffing box, anchoring means securing said stuffing box to said inner flange to thereby close said opening, cement mortar disposed on at least portions of said stuffing box and said frame, said cement mortar being disposed relative to said outer flange so as to form a circumferential groove between said cement mortar and said outer flange, whereby said groove provides access to said outer flange to facilitate affixing the latter to said structural member.

2. A structural unit body according to claim I wherein said frame is an integrally formed metal, boxlike structure.

3. A structural unit body according to claim 1 wherein said stuffing box is made of a dampproof mate rial, a metal net-like material covering said dampproof material, said noncombustible material being a fibrous material.

4. A structural unit body according to claim 3 wherein said mortar cement is disposed over and fixed to said metal net-like material and said inner flange, said mortar cement also being disposed on and fixed to a portion of said frame plate which is most closely adjacent to said inner flange, said mortar cement extending to form an edge disposed between said inner flange and said outer flange, said circumferential groove being defined by said edge and said outer flange.

5. A structural unit body according to claim 1 wherein said frame plate is provided with means defining a plurality of spaced openings.

6. A structural unit body according to claim 1 wherein said frame is an assembled, metal box-like structure.

7. A structural unit body comprising a frame having an outer flange and an inner flange, said inner flange circumscribing an opening in said frame, said outer flange being in the form of a U-shaped and box-like configuration, a buffer material disposed within said box-like configuration, a stuffing box, a noncombustible material within said stufiing box, anchoring means securing said stuffing box to said frame to thereby close said opening, cement mortar disposed on at least portions of said stuffing box and said frame, said cement mortar being disposed relative to said outer flange so as to form a circumferential groove between said cement mortar and said outer flange. IF 

1. A prefabricated structural unit body adapted to be affixed to a structural member comprising a four sided frame with each side having a frame plate along with an outer flange and an inner flange, said outer flange extending outwardly and said inner flange extending inwardly from said frame plate, said inner flange circumscribing an opening in said frame, a stuffing box, a noncombustible material within said stuffing box, anchoring means securing said stuffing box to said inner flange to thereby close said opening, cement mortar disposed on at least portions of said stuffing box and said frame, said cement mortar being disposed relative to said outer flange so as to form a circumferential groove between said cement mortar and said outer flange, whereby said groove provides access to said outer flange to facilitate affixing the latter to said structural member.
 2. A structural unit body according to claim 1 wherein said frame is an integrally formed metal, box-like structure.
 3. A structural unit body according to claim 1 wherein said stuffing box is made of a dampproof material, a metal net-like material covering said dampproof material, said noncombustible material being a fibrous material.
 4. A structural unit body according to claim 3 wherein said mortar cement is disposed over and fixed to said metal net-like material and said inner flange, said mortar cement also being disposed on and fixed to a portion of said frame plate which is most closely adjacent to said inner flange, said mortar cement extending to form an edge disposed between said inner flange and said outer flange, said circumferential groove being defined by said edge and said outer flange.
 5. A structural unit body according to claim 1 wherein said frame plate is provided with means defining a plurality of spaced openings.
 6. A structural unit body according to claim 1 wherein said frame is an assembled, metal box-like structure.
 7. A structural unit body comprising a frame having an outer flange and an inner flange, said inner flange circumscribing an opening in said frame, said outer flange being in the form of a U-shaped and box-like configuration, a buffer material disposed within said box-like configuration, a stuffing box, a noncombustible material within said stuffing box, anchoring means securing said stuffing box to said frame to thereby close said opening, cement mortar disposed on at least portions of said stuffing box and said frame, said cement mortar being disposed relative to said outer flange so as to form a circumferential groove between said cement mortar and said outer flange. 